Vibration Sensors

Vibration sensors, also widely known as piezoelectric sensors or piezo vibration sensors, are versatile tools for the measurement of various industrial processes. These sensors utilise the piezoelectric effect, which measures changes in pressure, acceleration, temperature, strain or force by converting them to an electrical charge, making them effective vibration monitoring sensors. A vibration sensor can also be used to determine aromas in the air by simultaneously measuring resonance and capacitance in specific applications.

Vibration sensor devices are ideal for measuring the amount and frequency of vibration in machines or equipment, particularly vibration sensors for motors and industrial machinery. The measurements obtained can then be used to detect and monitor certain issues like imbalances, helping to highlight future breakdowns in the machine. The range of vibration can vary greatly, from subtle fan vibrations to significant industrial vibrations, so you should always specify vibration sensors to accurately measure the maximum vibration range of your application.

Common Uses of Piezoelectric Sensors

Piezoelectric sensors are highly sensitive, compact devices that generate their own signal, making them ideal for a wide range of precise measurements. Their unique properties drive critical applications across diverse uses, including:

• Medical Industry: The high sensitivity of piezoelectric sensors is crucial in medical devices for precise pressure monitoring within the body, generating high-frequency sound waves for ultrasonic imaging and accurately measuring fluid flow rates for diagnostics and treatment.
• Engineers: Across mechanical, electrical and civil engineering, piezoelectric sensors serve as reliable tools for detailed vibration analysis in machinery, continuous structural health monitoring of buildings and bridges and accurate force measurement in product design and performance testing.
• Vehicle Designers: In the automotive industry, robust piezoelectric sensors, including sophisticated accelerometer vibration sensors, are fundamental to safety systems like airbag deployment triggered by sudden deceleration, detecting engine knock for optimal performance and monitoring vehicle vibrations to enhance ride quality and identify potential mechanical issues.
• Nuclear Technicians: The durability and reliability of piezoelectric sensors make them suitable for critical monitoring tasks within nuclear power plants, where they detect vibrations in reactors and other equipment to ensure operational safety, and to provide early warnings of potential malfunctions in demanding environments.

What is the Difference Between a Vibration Sensor and an Accelerometer?

The terms "vibration sensor" and "accelerometer vibration sensor" are often used interchangeably, as an accelerometer is a common type of device that detects vibration. However, an accelerometer specifically measures acceleration, from which velocity and displacement can be derived. Meanwhile, the broader category of "vibration sensor" can encompass various technologies measuring different aspects of vibration, such as direct velocity or displacement.

Therefore, it’s best to choose an accelerometer vibration sensor when direct acceleration measurement, especially at higher frequencies, is needed. Meanwhile, you should use a broader vibration sensor when your primary interest is in velocity or displacement, or for specialised detection of specific vibration characteristics.

Different Types of Vibration Sensors

To effectively monitor and analyse vibrations in various applications, a range of sensor types are available, each operating on different principles and offering unique advantages for specific measurement requirements. These include:

Fan Vibration Sensor

Fan vibration sensors are specifically designed to monitor the operational health of fans in various systems. Their primary role is to detect abnormal vibration levels that could indicate issues such as imbalance, bearing wear or misalignment. This enables proactive maintenance to prevent fan failure and to ensure the overall reliability of the system, whether it's in HVAC, industrial machinery cooling or electronic equipment.

Vibration Sensors for Motors

Vibration sensors for motors play a critical role in detecting mechanical faults that can lead to premature motor failure. By continuously monitoring vibration levels, these sensors can identify issues like misalignment, imbalance in the rotor or excessive bearing wear. Early detection allows for timely intervention, reducing wear and tear on the motor, preventing costly downtime and ultimately extending the motor’s lifespan.

Accelerometer Vibration Sensors

Accelerometer vibration sensors are a type of vibration sensor that specifically measures acceleration, with their key application lying in detecting high-frequency vibrations. This makes them particularly ideal for monitoring sensitive machinery and ensuring stable operation in high-precision environments. To maintain signal integrity, especially in demanding industrial settings, these sensors often utilise robust connection methods such as coaxial connectors.

Factors to Consider When Choosing a Vibration Sensor

Selecting the appropriate piezoelectric sensor or vibration monitoring sensor is crucial for obtaining accurate and reliable data that meets your needs. Carefully consider the following key factors:

• Vibration Range and Sensitivity: Consider the expected amplitude of vibration in your application to choose a sensor with an appropriate sensitivity level. Matching sensitivity to the vibration range ensures accurate readings without overloading the sensor.
• Frequency: Understand the dominant frequencies of vibration in your machinery or process. The vibration sensor’s frequency response should cover the entire range of interest to capture all relevant data for analysis.
• Temperature: High temperatures can affect the performance of vibration sensors. Consider the operating temperature range of your application and select a sensor that is rated for those conditions to maintain accuracy and longevity.
• Exposure to Chemicals or Debris: If the sensor will be exposed to chemicals, oil, dust or other debris, choose a robust industrial vibration sensor with appropriate sealing and material compatibility to ensure reliable long-term performance.
• Environmental Conditions: Consider the presence of flammable gases or dust. In such environments, intrinsically safe vibration sensors with certifications like ATEX or IECEx are mandatory to prevent explosions and ensure safety.
• Installation and Integration: Evaluate the physical constraints of your machinery, and choose a sensor with a suitable mounting style and connector type for easy and secure installation and integration with your vibration monitoring system.

Mistakes to Avoid When Buying Vibration Sensors

Selecting the wrong vibration sensor can lead to inaccurate data and ineffective monitoring. Make sure to avoid these common errors:

• Choosing the Wrong Type of Sensor: It's crucial to select a sensor based on the specific vibration characteristics you need to measure. For instance, using a basic piezoelectric sensor for very low-frequency industrial vibration that requires a displacement sensor, or opting for a low-frequency sensor when high-frequency analysis with an accelerometer vibration sensor is necessary, will yield inadequate results.
• Ignoring Compatibility with Equipment: Ensure the vibration monitoring sensor is compatible with your existing monitoring system, data acquisition hardware and software. Incompatible signal outputs, power requirements or communication protocols can prevent seamless integration and data analysis.
• Overlooking Measurement Range and Sensitivity: Failing to match the sensor’s specifications to the expected vibration levels is a common mistake. For example, choosing a low-sensitivity sensor for high-amplitude motor vibrations will lead to saturation, while a high-sensitivity sensor might not detect subtle fan vibration accurately.
• Not Considering Data Logging or Connectivity Needs: If you require historical data analysis or remote monitoring, verify that the vibration sensor or its associated system offers adequate data logging capabilities and connectivity options (e.g., wired, wireless) to suit your vibration monitoring requirements.
• Underestimating Environmental Conditions: Overlooking factors like temperature extremes, humidity, chemical exposure or the presence of dust and debris can significantly impact the performance and lifespan of vibration sensors. Selecting a sensor with appropriate environmental ratings is essential for reliable long-term operation in your specific industrial vibration environment.

Industry Applications

Industrial vibration sensors are indispensable tools for ensuring the reliability and efficiency of machinery across a multitude of industries. These include:

• Manufacturing: In manufacturing plants, industrial vibration sensors are extensively used for predictive maintenance on critical machinery like pumps, motors and turbines. Early detection of abnormal vibrations helps identify potential faults such as imbalance or misalignment, preventing costly downtime and extending equipment lifespan.
• Automotive: The automotive industry utilises vibration sensors for motors and other rotating equipment in production lines to ensure the quality and performance of manufacturing processes. Additionally, accelerometer vibration sensors are integrated into vehicles for active safety systems and ride comfort control.
• Aerospace: In the aerospace industry, vibration monitoring sensors are crucial for the health and safety of aircrafts. They monitor the structural integrity of airframes and the performance of critical components like engines and rotors, providing early warnings of potential mechanical issues.
• HVAC (Heating, Ventilation, and Air Conditioning): Fan vibration sensors and sensors on other rotating equipment in HVAC systems detect imbalances and bearing failures. Often connected to data loggers, these sensors track vibration trends, enabling optimised maintenance schedules for energy efficiency and preventing system breakdowns in buildings and industrial facilities.

Your Trusted Vibration Sensor Supplier and Manufacturer in Australia

RS Australia is a trusted and widely used supplier of high-quality vibration sensors across Australia. We partner with leading manufacturers like SKF and Fluke to offer a comprehensive range of reliable and accurate sensors, including industrial vibration sensors, piezoelectric sensors and accelerometer vibration sensors. Alongside our diverse selection, we also offer associated products such as work gloves and flow sensors.

Choosing RS Australia means you’ll also gain access to competitive prices, fast, Australia-wide delivery, and dedicated technical guidance and customer support. Plus, we offer flexible payment and shipping solutions to suit your all needs, with detailed information on all our delivery options available on our Delivery Information page. Equip your operations with precise vibration monitoring solutions — buy your vibration sensors from RS Australia today!